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Automatic Baggage Handling System Explosives Detection:

Fast Automation consulted to and represented Siemens A&L in a $70m automation project at Sydney Airport to automatically detect explosives in the baggage handling system (BHS) in both T1 and T2. This allowed Sydney Airport to 100% screen all checked baggage for explosives using EDTS (5 beam Explosive Detection Tomography System).

http://www.airport-int.com/categories/xray-security/securitynet-the-shape-of-things-to-come.asp

The project involved supplying and programming of 15 New Siemens S7-400 PLCS, Modifications to several other PLC’s  and 2 unlimited Citect SCADA redundant servers with 25 clients.

Primary Tasks included:-

  1. URS (User Requirements Analysis) analysis
  2. FDS (Functional Design Specifications) development
  3. DDS (Detailed Design Specifications) development
  4. Code development
  5. Bespoke baggage movement PLC Simulation system development
  6. FAT (Factory Acceptance Testing) planning, documentation of and hosting
  7. SAT (Site Acceptance Testing) planning, documentation of and hosting
  8. PD (Performance Demonstration) development of logging systems and automatic report generators.
  9. Preparation and execution of QMP Quality Management Plan
  10. Implementation of conducive methodologies
  11. Multiple subcontractor co-ordination and management
  12. Preparation and chairing of weekly automation progress meetings
  13. Issues Management
  14. Development of Automated test plans and result sets

This project required the addition (into a space that was not designed for it) of 5 kilometers of conveyor and 13 EDTS machines.

One of the primary challenges of the project was cutting into the existing baggage handling system and commissioning in small time windows without any disruption to the airports normal operations.

Basically bags that were checked in were diverted and routed through 3D EDTS x-ray machines. The x-ray machines automatically detect suspect bags (termed level 1 failures) then present the suspected bags to a control room of trained inspectors. During the period of inspection the suspect bags go through several levels of decisions, these decisions are also physical areas in the baggage handling system (the 5 th level being a bomb-room).
In addition there are a myriad of other equipment and scenarios that further complicate the solution.   
One of the primary challenges of the project was cutting into the existing baggage handling system and commissioning in small time windows without any disruption to the airports normal operations.

Technology used:
Siemens S7-4xx and S7-3xx PLC Systems Coded in Step7 (STL, LAD, FBD and SCL languages)
Siemens Wincc SCADA Version 6 (utilized for PD monitoring and simulation)
Citect SCADA (V6.2) (BHS Primary SCADA system)
Accusort Barcode Scanner Arrays.
Siemens Ecofast High Feature Motor Controllers (On Profibus DP)
Remote I/O units ET200eco, ET200L, ET200s and ET00M variants.
ASi (addition to existing systems)
Danfoss VSD’s
Datalogic Dragon Barcode hand scanners interfaced over Profibus DP
Multiple Serial and Ethernet Communications Interfacing  to peripheral devices.

Project Images:

Image of the recorded throughput in one area using Fast Automation's software. This image highlights that one xray machine's output was blocking then clearing.:

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Image of generic simultation test rig designed and put together by Fast Automation:

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Screen Shot of the actual Traceability matrix used to ensure compliance to requirements policed by Fast Automation:

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Image of atomatically generated and emailed reports created by Fast Automations software:

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BHS actual scada screens, using Citect's SCADA application:

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Issues management using Xylogy project governance system.


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Typical Code Change Request Form sample:

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Example of PLC Hardware configuration using Step-7:

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Brochure image of some of the remote Siemens Hardware used:

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